Safetyo Assembly o Operation oTips & Techniques oMaintenance * Troubleshooting o Parts Lists oWarranty

®

21-inch Rotary Mower -- Model Series 836

READ SAFETY RULES AND mNSTRUCTmONS CAREFULLY BEFORE OPERATION

Warning: This unitis equippedwithan internalcombustionengineandshouldnot beusedon or nearany unimprovedforest-covered,brush=coveredor grass=coveredlandunlessthe engine'sexhaustsystemis equippedwitha sparkarrestermeetingapplicablelocalorstate laws(if any),If a sparkarresteris used, it shouldbemaintainedineffectiveworkingorderby the operator,Inthe Stateof Californiathe aboveis requiredbylaw(Section4442of the CaliforniaPublicResourcesCode),Otherstatesmayhavesimilarlaws,Federallawsapplyonfederallands,A sparkarresterfor the muffleris availablethroughyournearestengineauthorizedservicedealeror contactthe servicedepartment,RO,Box361131Cleveland,Ohio44136=0019,

PRINTEDIN U,S,A MTD LLC, RO. BOX 361131 CLEVELAND, OHiO 44136-0019 FORMNO,769=01541B11/29/2005

This Operator's Manua_ is an important part of your new lawn mower. JtwH_ he_p you assembJe,

prepare, and maintain the unit for best performance. P_ease read and understand what it says.

Table of ContentsSJope Gauge ....................................................... 3Safe Operation Practices ................................... 4

Setup and Adjustment ....................................... 6Operating Your Lawn Mower .............................. 8Maintaining Your Lawn Mower ......................... 10

Troub{eshooting ................................................ 14Safety Labels .................................................... 15Parts List ........................................................... 16

Warranty ............................................ Back Cover

Finding and Recording Model Number

BEFOREASSEMBLINGYOUR NEW EQUIPMENT,please

locate the model plateon the equipmentand copy theinformation to the sample model plate providedto the right.

Youcan locate the model plate by standing at the operatingposition and lookingdown at the rearof the deck. This infor-mation will be necessary to use the manufacturer'sweb site,

obtain assistance from the Customer Support Department, orwhen contacting an authorizedservice dealer.

Modet Number Serial Number

O TRI:IItf B#LT' TRO¥-BULTLLCP. O. BOX 361131www.troybimt.com CLEVELAND,OH44136

338-558-7228

Customer Support

P_ease DO NOT return the unit to the retai_er from which it was purchased without first

contacting Customer Support.

If you havedifficulty assembling this product or have any questions regardingthe controls,operation, or maintenanceof thisunit, you can seek help from the experts. Choose from the options below:

1. Visit www.troybilt.com

2. Phonea CustomerSupport Representativeat 1o866o840o6483.

3. The engine manufacturer is responsible for all engine-relatedissues with regards to performance,power-rating,specifica-tions, warranty, and service. Please refer to the engine manufacturer'sOwner's/Operator's Manual, packed separatelywithyour unit, for more information.

2

yourlawnmoweronsuchslopes.

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/

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to

w_

WARNING

Do not mowon inclines

with a dope in excessof 15 degrees (a riseof approximately2-"

feet). A riding rcould overturnand

cause serious injury.

if operatinga walbbehind mower on such

a dope, it is extremely

footing and you coulddip, resulting in serious

injury.

Operate RiDiNGmowers up and down

dopes, neveracrossthe face of dopes.

OperateWALK-BEHIND

mowers across the

face of dopes, neverup and down slopes.

\

3

manual.Aswithanytypeofpowerequipment,carelessnessorerroronthepartoftheoperatorcanresultinseriousinjury.Thismachineiscapableofamputatinghandsandfeetandthrowingobjects.

! Failuretoobservethefollowingsafetyinstructionscouldresultin seriousinjuryordeath.

endangerthepersonalsafetyand/orproperty

ChildrenTragicaccidentscan occurifoperatoris notalert to presenceof children.Childrenare oftenattractedto mowerandmowingactivity.They donot understandthe dangers.Neverassumethatchildrenwill remainwhereyou lastsawthem.

1. Keepchildrenoutof the mowingareaandunderwatchfulcareof a responsibleadultotherthanthe operator.

2. Be alert andturn moweroff ifa childentersthearea.

3. Beforeand whilemovingbackwards,look behindanddownforsmallchildren.

4. Useextremecare whenapproachingblindcorners,doorways,shrubs,trees,orotherobjectsthat mayobscureyourvisionof a childwho mayrun into themower.

5. Keepchildrenawayfromhot orrunningengines.Theycansufferburnsfroma hotmuffler.

6. Neverallowchildrenunder14yearsoldto operatea powermower.Children14yearsold andovershouldreadandunderstandoperationinstructionsandsafetyrulesin thismanualandshouldbe trainedandsupervisedbya parent.

General Operation1. Readthis operator'smanualcarefullyin its entiretybefore

attemptingto assemblethis machine.Read,understand,andfollow all instructionson the machineandin the

manual(s)beforeoperation.Be completelyfamiliarwiththecontrolsandthe properuseof this machinebeforeoperatingit.Keepthis manual in a safeplaceforfutureand regularreferenceandfor orderingreplacementparts.

2. Thismachineis a precisionpieceof powerequipment,nota plaything.Therefore,exerciseextremecautionat alltimes.Yourunit hasbeen designedto performonejob: tomowgrass.Do notuse itfor anyotherpurpose.

3. Neverallowchildrenunder 14yearsold to operatethismachine.Children 14yearsold and overshould readandunderstandthe instructionsinthis manualandshould

be trainedand supervisedbya parent.Only responsibleindividualswho arefamiliar withthese rulesof safe

operationshould beallowedto use this machine.

4. Thoroughlyinspectthe areawherethe equipmentis tobeused. Removeall stones,sticks,wire, bones,toys andotherforeignobjectswhichcould betripped overor pickedupand thrownby the blade.Thrownobjectscancauseseriouspersonalinjury.Planyourmowingpatternto avoiddischargeof materialtowardroads,sidewalks,bystandersandthe like.Also, avoiddischargingmaterialagainstawall orobstructionwhich maycausedischargedmaterialto ricochetbacktoward theoperator.

6. Alwayswear safetyglassesor safetygogglesduringopera-tionandwhile performinganadjustmentor repairto protectyoureyes.Thrownobjectswhich ricochetcancauseseriousinjury to the eyes.

7. Wearsturdy, rough-soledworkshoesand close-fittingslacksandshirts. Shirtsand pantsthat coverthe arms andlegs andsteel-toedshoesare recommended.Neveroperatethis machinein bare feet,sandals, slipperyor lightweight(e.g.canvas)shoes.

8. Do notputhands or feet near rotatingparts or undercuttingdeck.Contactwithblade canamputatehands andfeet.

9. A missingor damageddischargecovercancausebladecontactor thrownobject injuries.

10.Manyinjuriesoccur asa resultof the mowerbeing pulledoverthefoot duringa fall causedby slippingor tripping.Do notholdon to the mower if youare falling; releasethehandle immediately.

11.Neverpullthe mowerback towardyouwhileyouarewalking.If youmustback the mowerawayfroma wall orobstructionfirst look downandbehind to avoidtrippingandthenfollow thesesteps:

a. Stepback frommowerto fully extendyour arms.

b. Be sureyou arewell balancedwithsure footing.

c. Pullthe mowerbackslowly,no morethan halfwaytowardyou.

d. Repeatthese stepsas needed.

12.Do notoperatethe mowerwhileunderthe influenceofalcoholor drugs.

13.Do notengage theself-propelledmechanismon units soequippedwhilestartingengine.

14.The bladecontrolhandleis a safetydevice.Neverattemptto bypassits operation.Doingso makesthe safetydeviceinoperativeandmay resultinpersonal injurythroughcontactwiththe rotatingblade.The bladecontrolhandlemustoperateeasily in bothdirectionsandautomaticallyreturnto the disengagedpositionwhenreleased.

15.Neveroperatethe mowerinwet grass. Alwaysbesure ofyourfooting. A slipand fallcan causeseriouspersonalinjury.If you feel youare losingyour footing,releasethebladecontrolhandle immediatelyandthe bladewillstoprotatingwithinthreeseconds.

16.Mowonly indaylightor good artificial light.Walk,never run.

17.Stopthe bladewhencrossinggraveldrives,walksor roads.

18. If the equipmentshouldstart to vibrateabnormally,stoptheengineandcheck immediatelyforthe cause.Vibrationis

and follow the warnings 5. Tohelpavoidbladecontact ora thrownobjectinjury, ._ generallya '_arningof !rouble.. .......]_ _nut the engne errandwar unl: me Daaecomes-coaand i..struction2 stay inoperatorzone behindhandlesandkeepchildren, "

u _ compete stop beforeremovng the grasscatcheror uncog, ,; bystanders,helpers,andpetsat least75 feet frommower .un_nusmanuau glngthechute

whileit is in operation.Stopmachineifanyoneenters

and on the machine, area...... ,J

4

The cutting bladecontinuesto rotatefor a fewseconds afterthe engine is shutoff. Neverplaceanypart of the bodyinthe blade areauntilyouare surethe blade hasstoppedrotating.

20.Neveroperatemowerwithoutpropertrailshield,dischargecover, grasscatcher,bladecontrolhandle,or othersafetyprotectivedevices in placeandworking.Neveroperatemowerwithdamagedsafetydevices.Failureto do socanresultin personalinjury.

21.Mufflerandenginebecomehotand cancausea burn.Donot touch.

22.Onlyuseparts and accessoriesmadefor this machinebymanufacturer.Failureto doso can result inpersonalinjury.

23. If situationsoccurwhichare not coveredin this manual,usecareand goodjudgment.Contactyour dealerforassistance.Telephone1-866-840-6483forthe nameof yournearestdealer.

SJope OperationSlopesare a majorfactor relatedto slipandfallaccidentswhichcan resultinsevereinjury.Operationonslopesrequiresextracaution.Ifyou feeluneasyona slope,donotmow it.Foryoursafety,use the slopegaugeincludedas part of this manualtomeasureslopesbeforeoperatingthis unit ona slopedor hillyarea.If theslopeis greaterthan 15degrees,do notmowit.

Do:

1. Mowacrossthe faceof slopes;neverup anddown.Exerciseextremecautionwhenchangingdirectiononslopes.

2. Watchfor holes,ruts, rocks,hiddenobjects,or bumpswhichcan causeyou to slipor trip.Tall grasscan hideobstacles.

3. Alwaysbesure of yourfooting.A slip andfall cancauseseriouspersonalinjury.If you feel youare losingyourbalance,releasethe blade controlhandle immediately,andthe blade willstop rotatingwithin 3 seconds.

Do Not:

1. Do notmowneardrop-offs, ditchesorembankments,whereyou could loseyour footingorbalance.

2. Do notmowslopesgreaterthan 15degreesas shownonthe slopegauge.

3. Do notmowon wetgrass. Unstablefootingcouldcauseslipping.

Service

Safe Handling Of Gaso%e:1. To avoidpersonalinjury or propertydamageuseextreme

care in handlinggasoline.Gasolineis extremelyflammableandthevaporsare explosive.Seriouspersonalinjurycanoccurwhengasolineis spilledonyourselforyour clotheswhich can ignite.

2. Washyour skinand changeclothesimmediately.3. Useonly anapprovedgasolinecontainer.4. Neverfill containersinsidea vehicleor ona truckor trailer

bedwith a plasticliner.Alwaysplacecontainerson thegroundawayfromyourvehiclebeforefilling.

5. Removegas-poweredequipmentfromthe truck or trailerandrefuel it on the ground. Ifthis is notpossible,then refuelsuchequipmentona trailerwitha portablecontainer,ratherthan froma gasoline dispensernozzle.

6. Keepthe nozzlein contactwith therim of thefuel tank orcontaineropeningat all timesuntil fuelingis complete.Donotusea nozzlelock-opendevice.

7. Extinguishall cigarettes,cigars, pipesandothersourcesof ignition.

8. Neverfuel machineindoorsbecauseflammablevaporswillaccumulatein the area.

9. Neverremovegascap oradd fuelwhileengine is hot orrunning. Allowengineto cool at least two minutesbeforerefueling.

10.Neverover fill fuel tank. Fill tankto nomorethan _ inch

belowbottom of filler neckto providefor fuel expansion.

11.Replacegasolinecapandtightensecurely.

12. If gasolineis spilled,wipe it off the engineand equipment.Moveunit to anotherarea.Wait5 minutesbeforestartingengine.

13.Neverstore the machineor fuel containernearanopenflame,spark orpilot light as ona water heater,spaceheater,furnace, clothesdryer,orothergas appliances.

14.Toreducefire hazard,keepmowerfree of grass, leaves,or otherdebrisbuild-up.Cleanupoil or fuel spillageandremoveanyfuel soakeddebris.

15.Allowa mowerto cool at least5 minutesbeforestoring.

General Service:

1. Neverrun anengineindoorsor ina poorlyventilatedarea.Engineexhaustcontainscarbonmonoxide,an odorlessanddeadlygas.

2. Beforecleaning,repairing,or inspecting,makecertainthebladeandall movingparts havestopped.Disconnectthesparkplugwire andgroundagainsttheengineto preventunintendedstarting.

3. Checkthe bladeandenginemountingboltsatfrequentintervalsfor propertightness.Also,visually inspectbladefordamage(e.g.,bent, cracked,worn)Replacebladewiththeoriginalequipmentmanufacture's(O.EM.) bladeonly,listedinthis manual."Useof parts whichdo notmeettheoriginalequipmentspecificationsmayleadto improperperformanceandcompromisesafety!"

4. Mowerbladesare sharpandcancut.Wrap thebladeorweargloves,anduseextracautionwhenservicingthem.

5. Keepallnuts,bolts,andscrewstight to besurethe equip-ment is in safeworkingcondition.

6. Nevertamperwithsafetydevices.Checktheirproperopera-tion regularly.

7. Afterstrikinga foreignobject,stopthe engine,discon-nectthe spark plugwire andgroundagainsttheengine.Thoroughlyinspectthe mowerfor anydamage.Repairthedamagebeforestartingandoperatingthe mower.

8. Neverattempt to makea wheelorcutting height adjustmentwhilethe engineis running.

9. Grasscatchercomponents,dischargecover,and trailshieldare subjectto wear anddamagewhichcould exposemovingparts orallow objectsto be thrown.Forsafetyprotection,frequentlycheckcomponentsand replaceim-mediatelywithoriginal equipmentmanufacturer's(O.EM.)parts only,listed in this manual."Useof partswhich donot meettheoriginal equipmentspecificationsmayleadtoimproperperformanceandcompromisesafety!"

10.Donot changetheenginegovernorsettingor overspeedtheengine.The governorcontrolsthe maximumsafeoperatingspeedof the engine.

11.Maintainor replacesafetylabels,as necessary'.

12.Observeproperdisposallawsand regulations.Improperdisposalof fluidsand materialscanharmtheenvironment.

w o°,°oThis Symbolpoints

ua! before attempting to

resuUt in personal injury_::When you see th s

_symbol

,EEDMTSWARNmNG

ResponsibilityRestrict the use

of this power machineto persons who read

understand

5

Stand behind the

moweras if you weregoing to operate it,

respondsto the rightside of the mower;your

eft hand correspondsto the left side of the

mower.

For shipping purposes

your mower is set withthe wheels in a low

cutting height position.For best results rase

the tutti ng positionuntil it is determinedwhich heiaht is best

for your lawn, refer to

instructions,

IMPORTANT

DO NOT crimp thecanes when lifting the

handb up.

iMPORTANT

without gasoline or

up gasoline and oilas instructed in the

accompanyingenginemanual BEFORE

operating your mower,

HandleMounting

Figure3-1:Unfoldhandleandtightenhardware,

f

Figure3-2:Securehandleto handlemountingbrackets,

as shownin Figure34. Makecertain the lowerhandleis seatedsecurelyinto the handlemountingbrackets.

b. Tightenhandknobssecuringupperhandletolowerhandle.Makesure thateach carriagebolt isseatedproperlyin the handb.

2. Replaceandtightenhandknobsremovedearlbrsecuringlowerhandb to handlebrackets,Figure3-2.

3. The ropeguideis attachedto the right sideof theupperhandle.Loosenthe wingnut whichsecurestheropeguide,Figure3-3.

a. Holdthe bladecontrolagainstupperhandle.

b. Pullstarterropeoutof the engine.Releasethebladecontrol.

c. Slipstarterropeintoropeguide.

d. Tightenwingnut.

4. Securecanes to the lowerhandb usingthe cane tie.Pullcane tie tightandcutoff excess.

5. Toassembb the grasscatcher(if needed),placebagoverframewith the blackplastb sideat the bottom.Slipplastb channeloverhooksonframe.All channelsexceptfor centertop of bagattachfromthe outside.Thecenterof bagattachesfromthe inside.

6. Beforeattachingthe grasscatcher,the mulchingbafflemustberemoved,Figure3-5.

a. Lift reardischargedoor.

b. Removemulchingbaffle.

7. Toattachgrasscatcher,Figure3-4.

a. Lift reardischargedoor.

b. Placegrasscatcheronthe pivot rod.Let goof dischargedoorso that it restsonthe grasscatcher.

Figure3-3:Pullrecoilstarterthroughropeguideandtighten. Figure3-4:Liftdischargedoorandplacegrasscatcheronrod.

6

8. The batterypackwithin the ElectricStartermustbecharged8 to 10hoursbeforeuse.Referto "ChargingBattery"in the Maintenancesectionfor instructions.

9. Followthe stepsbelowto install the mulchingbaffle:

a. Lift the reardischargedoorandlift the grasscatcherupandoff ofthe pivotrod, if installed.

b. Insertthemulchingbaffleas showninFigure3-5and releasethe reardischargedoor.

10.Toconvertto side discharge,makesure grasscatcheris offof the unitandreardischargedoor is closed.

a. On theside of the mower,lift the mulchingplug.

b. Slidetwo hooksonside dischargechuteunderhingepin onmulchingplugassembly,Figure3-6. Lowerthemulchingplug.Do not removeside mulchingplugat any timeevenwhenyou arenot mulching.

JFigure3-5:Themulchingbaffle Figure3-6:Installingthesidedischargechute.

AdjustmentsCutting HeightThe cuttingheightadiustmentleveris locatedabovethe rear leftwheel,Figure3-7.

a. Pullthe leverout andawayfromthe mower.

b. Movethe leverforwardor backfor desiredcuttingheight.

c. Releaselevertowardsmowerdeck.

Drive ControlThe adiustmentwheelis locatedinthe drivecontrolhandlehousingandis usedto tightenor loosenthedrive belt.Youwill needto adiust thedrivecontrol if the mowerdoesnot propelitselfwith the drivecontrolengagedor if themower'swheelshesitatewith the drivecontrolengaged.If eitherof theseconditionsoccur,rotatethe adiustmentwheelclockwiseto tightenthe cableor counterclockwiseto loosenthe cable,Figure3-8.

,,%f

/'

the grass.

drive control may not

post on You can adjust

the handle by tighteningthe adjustment wheeL

i

Figure3-8:Theadjustmentwheelonthedrivecontrol.

7

Know Your Lawn MowerDrive Control

WARNING

The blade control

mechanism is a

safety device. Never

attempt to bypass its

operations.

Use extreme care

when handlinggasoline. Gasoline isextremely flammabb

and the vapors areexplosive. Neverfuelthe machine indoors

or while the engineis hot or running.

Extinguish cigarettes,cigars, pipes andother sources of

ignition.

Keep hands and feet:way from the chute

tea on cutting deck.

Refer to warningJabelon the unit.

Oil Fill

Figure4-1:The majorcomponentson the mower.

Now that you have setup your lawn mower for op-eration, it's important to become aquainted with itscontrols and features.

B_ade Contro_The blade control is attached to the upper handleof the mower. Depress and squeeze it against theupper handle to operate the unit. Release it to stopengine and blade.

WARNING: The blade control is a safety

device. Do not bypass its operation.

Drive Contro_The drive controi is Iocated on the upper handIe.Squeeze the drive control Iever to engage the drivesystem. ReIease it to disengage the drive system.To slow down when approaching an obstacle, mak-ing a turn, or stopping, release the lever.

Cutting Height Adjustment LeverThe cutting height adiustment lever is locatedabove the left rear wheel To adjust the cuttingheight, refer to the Adiustment Section.

Recoi_ StarterThe recoiI starter is attached to the right upperhandle. Stand behind the unit and puII the recoilstarter rope to start the unit.

E_ectrie StarterThe ignition switch is located on the Ieft side ofthe electric starter handle panel. It is necessary tocharge the battery for 8 to 10 hours before initial use.Refer to the Maintenance section for more informa-tion.

FreshStart TM Gas Cap (if Equipped)This unit may be equipped with a FreshStart TM con-tinuous fuel preserver gas cap which automaticallydrips continuous fuel preserver into your fuel tank forup to six months depending on conditions, such astemperature, usage patterns, fuel type and blend. Toactivate the gas cap, follow the instructions below:

1, Snap the fuel preserver cartridge that comes with your

unit into the fuel cap,

2, Peel off the white tab from the cartridge,

3, Twist the FreshStartTM cap onto the fuel tank,

When you visually see that the fuei preserver car-tridge is empty, replacement cartridges are availablethrough your local service deaIer.

Gas and Oi_ Fii{-Up1, Check oil level and add oil if necessary, Follow engine

manual for this,

2, Service the engine with gasoline as instructed in the

engine manual

Mu_ching P_ugThe mulching plug is used for mulching purpose,

Instead of colbcting the grass clippings in the grass

catcher, your mower has the option of recirculating

the clippings back to the lawn, Make sure that the

rear discharge door is closed and the grass catcher is

removed from unit while mulching,

WARNING:Usee×trernecare when

handling gasoline. Gasoline is e×tremelyflammable andthe vapors are explosive.

Never fuel the machine indoors or while the engine ishot or running. Extinguish cigarettes, cigars, pipesand other sources of ignition.

8

WARNING:Theoperation of any lawn flmower can result inforeign objects being

thrown intothe eyes, which can damageyour eyes severely.Always wear safety glasseswhile operating the moweror while performing anyadjustments or repairs on it.

1. Pushprimerthreetimes.Waitabouttwosecondsbetweeneachpush,Figure4=2.In temperaturearound55°For below,primefivetimes.Do notprimeto restarta warmengine.

2. Standingbehindthe mower,squeezethe bladecontrolagainstupperhandle,Figure4=2.

3. RecoilStart: Grasprecoilstarterhandleandpull ropeout witha rapid,continuous,fullarm stroke,Figure4=2.Keepinga firmgripon thestarter handle,let theroperewindslowly.Repeatuntil enginecranks.Lettheroperewindeachtimeslowly.

Electric Start: Turnignitionkeyto the rightto starttheengine,Figure4=2.Releasethe keyafter the enginestarts.

Stopping Engine

1. Releasebladecontrol to stopthe engineandblade.

2. Disconnectsparkplugwire fromsparkplugandgroundagainstthe engine.

WARNING:Wait for the bladeto stopcompletely before doing any work on themower or to removethe grass catcher.

Using Your Lawn MowerWARNING:Neveroperate your mowerwithout either the rear door or the entire

grass catcher assembly firmly secured.Be surelawnis dear of stones,sticks,wire,or otherobiectswhichcoulddamagelawnmowerorengine.Suchobiectscouldbe accidentlythrownby the mowerin anydirectionandcauseseriouspersonaliniuryto theoperatorandothers.

Figure4-2:Startingthe mower.

_ ARNING:If you strike aforeign object,stop the engine. Removewire from thespark plug,thoroughly inspectmower

for any damage,and repair damage before restart-ingand operating. Extensive vibration of mowerduring operation is an indicationof damage.Theunit should be promptly inspectedand repaired.

1. Oncethe engineis running,squeezethe drivecontrolagainstthe upperhandleto propelmower.

• For bestresults,do notcut wetgrass.

. Fora healthierlawn,nevercutoff morethanone=thirdof the total lengthof the grass.

Using as MulcherFormulchinggrass,removethe grasscatcherfromthe mowerand installthe mulchingbaffle.The reardischargedoorshouldbeclosed.

• Foreffectivemulching,do notcut wetgrass.

• Neworthickgrassmayrequirea narrowercut.Adiustgroundspeedaccordingto conditionof lawn.

• if thegrasshas beenallowedto growinexcessof4 inches,mulchingis not recommended.Usethegrasscatcherto bagclippingsinstead.

Using Grass CatcherYoucan usethe grasscatcherto collectclippingswhileyouareoperatingthe mower.Referto Setupsectionforinstallationinstructions.

Grassclippingswill automaticallycollect inbagasyourun mower.Operatemowertill grassbagis full.

. Stopenginecompletelyby releasingthebladecontrol Makesure that the unit hascometo a

moving partsoneng!neand awn mower.

comp otestopd schargodoorandgrassbagupandawayfromthe mowerto disposeof the grassclippings.

9

f "_ Lubrication

i ii

IMPORTANT: The use

of a pressure washer

eUectricComponents,

\Figure5-1:Lubricationareasonthemower.

f

Figure5-2:Replacingthe rearflap.

General Recommendations• Alwaysobservesafetyruleswhen performing

any maintenance,

Thewarrantyon this lawnmowerdoes notcoveritemsthathavebeensubjectedto operatorabuseor negligence,Toreceivefull valuefromwarranty,operatormustmaintainthe lawnmowerasinstructedhere,

, Changingofengine-governedspeedwill voidenginewarranty,

, Alladiustmentsshouldbecheckedat leastonceeachseason,

• Periodicallycheckall fastenersand makesurethesearetight,

WARNING:Always stop engine, discon-nect spark plug, and ground againstengine before cleaning, lubricating or

doing any kind of maintenanceon your machine.

1, Lubricatepivotpointson the bladecontrolat leastoncea seasonwith lightoil The bladecontrolmustoperatefreely inboth directions,Figure54,

2, Lubricatethe wheelsat leastoncea seasonwithlightoil (or motoroil), Ifwheelsare removedfor anyreason,lubricatesurfaceof the axleand innersurfaceof the wheelwith lightoiL

3, Lubricatethe torsionspringandpivotpointonthe reardischargedoorandside mulchplugperiodicallywithlightoil to preventrust,

4, Thetransmissionis pre-lubricatedandsealedat thefactoryanddoes notrequirelubrication,

5, Followthe accompanyingenginemanualfor lubrica-tionscheduleandinstructionfor enginelubrication,

Deck Care1, Disconnectsparkplugwire,Draingasolinefromlawn

mowerorplacea pieceof plasticunder thegas cap,

2, Tip mowerso that it restson the housing,Keepthesidewith the aircleanerfacingup,Hold mowerfirmly,

WARNING:Never tip the mower morethan 90degrees inany directions and donot leavethe mowertipped for any length

of time. Oil can drain intothe upper partofthe enginecausing a starting problem.

3, Scrapeandclean the undersideof the deckwithasuitabletool,Do notspraywithwater,

4, Putthe mowerbackonits wheelsonthe ground,Ifyou hadput plasticunderthe gas capearlier,makesureto removeit now,

Engine Care, Maintainoil levelas instructedin enginemanual,

, Serviceaircleanerevery25 hoursundernormalconditions,Cleaneveryfewhoursunderextremelydustyconditions,Referto enginemanual

, Cleansparkplugandreset thegap oncea season,Checkenginemanualfor correctplugtype andgapspecifications,

• Cleanengineregularlywitha clothorbrush,Keepthecoolingsystem(Newerhousingarea)cleanto permitproperaircirculation,Removeallgrass,dirt andcombustibledebrisfrom mufflerarea,

Replacing Rear F_ap1, Lift upreardoor,

2, Bend(bow)the rearflap inwardon eachside toreleasetabsfromthe holesin the handlemountingbrackets,Figure5-2,

3, Replacewith newflap bybendingthe rear flapandslidinginto place,

10

the carburetorareup,

2, Removebolt,bladebellsupport,blade,andadapterfromthe enginecrankshaft,Figure5=3,

NOTE:Whenremovingthe blade,adapter,etc,,becare=ful notto removeor misplacepartsaboveit associatedwith the enginepulley,

3, The bladecan be sharpenedwitha file oron agrind=ingwheel Do notattemptto sharpenthe bladewhileit is stillon the mower,Whensharpeningblade,followoriginalangleof grind,Grindcuttingedgesequallytokeepbladebalanced,

4, Removebladefromthe adapterfor testingbalance,Balancethe bladeona roundshaftscrewdriverto

check,Removemetalfromthe heavyside untilitbalancesevenly,

WARNING:An unbalanced blade willcause excessivevibration when rotatingat high speeds. It maycause damageto

mower, and could breakcausing personalinjury.

5, Lubricatetheenginecrankshaftandthe innersurfaceof the bladeadapterwith lightoil Slidethe bladeadapterontotheenginecrankshaft.Placethe bladeon the adaptersuchthat theside of the blademarked"Bottom"(orwithpart number)facesthe groundwhenthe moweris in the operatingposition,Makesurethatbladeis alignedandseatedon bladeadapterflanges,

6, Placebladebellsupporton the blade,Alignnotcheson the bladebellsupportwithsmallholesin blade,Replacehexbolt andtightenhex boltto torque:450in, Ibs,min,,600 in, Ibs,max,

Toensuresafeoperationof yourmower,periodicallycheckthe bladeboltfor correcttorque,

Belt Care

1, Disconnectsparkplugwire andgroundagainstengine,

2, Drainthe fuel tankorplacea pieceof plasticbeneaththe cap to preventgasolineleakage,

3, Tip moweron itsside (aircleanerside of engineup),

4, Removeblade,bladeadapter,and relatedhardware,Figure5=3,

5, Loosenself=tappingscrewthat securesdeckbaffletothe deck, Figure5=4,

6, Workingfromthe rearof the mower,carefullyremovebeltfromtransmissionpulley,

JFigure5-3:Removethebolt,support,blade,andadaptertoaccessthebladeandundersidecomponents.

j J/

Figure5-4:Removescrewholdingbaffletodeck.

f

/ ......... ;_:;_........... "

.........i ¸¸

Figure5-5:Removebeltfromtransmissionthenengine.

7, Oncebelt is off transmissionpulley,pushdownondeckbaffleto accessenginepulleyandslide belt offthispulleyandout fromunderthe deck,Figure5=5,

8, Replacewith newbelt,workingit betweenthe deckandbaffle,firstaroundthe transmissionpulleyandthenthe enginepulley,Tightenscrewloosenedearlierandreplacebladeandhardware,

9, Tip mowerbackonto itswheelsand removepieceofplasticfromundergascap (ifapplicable),

11

WARNING ;

When removingthe cutting blade

for sharpening or

replacement orwhen sliding the beltaround it, protect

your hands with apair of heavy gloves

or use a heavy rag tohold the blade.

An unbalancedblade will causeexcessive vibration

when rotating at highspeeds, it may cause

damage to mower and

could breakcausingpersonaJ injury.

Make certain that bert

is seated correctlyand that it is ridingsmoothJy on the en-

gine pulley and isnot pinched between

the lower and upperpulley halves.

WARNING

Batteries contain

sulfuric acid which maycause burns. Do notshort circuit or mutilate

batteries in any way. Donot put batteries in fireas these may buret orreleasetoxic materials.

Useonlythe batterycharger supplied withthis mower,

Do not removethebattery packfrom theelectric starter housingfor any reason otherthan replacement.

release toxic materials.

1. Loosenroundhandleknobssecuringupperandlowerhandlesandcarefullyfold the upperhandledowntowardthe lowerhandleas showninFigure5=3.

2. Removethetwoscrewssecuringbatterycovertobatteryhousingandplacethemto the side,Figure5=3.

3. Openbatterycover,removepositiveandnegathfeleadsfrombattery,removeandreplacewith newbattery,Figure5-4. Connectthe positiveleadto thepositiveside of the batterypack,then connectthenegativeside.

NOTE:The batteryyou havemaydifferslightlyfromtheoneshownin Figure5-4. Referto the PartsList.

IMPORTANT:When replacing battery pack inhandlepanel, battery pack must be positioned with thepositive terminal to the left side and the negativeterminal to the right side of panel (Positive terminalis closest to the key switch}, Figure 5°4.Replacingbattery pack incorrectly will causeserious damage.

4. Reattachbatterycoverto batteryhousingbysecur-ingwith the twoscrewsremovedearlier,makingsureto snapthe wireconduiton the left intoplaceonthehousing.

5. Foldhandlesbackupand tightenhandleknobs.

Charging BatteryWARNING:The battery contains corroosire fluid and toxic material; handle withcare and keep awayfrom children. Do

not puncture, disassemble, mutilate or incineratethe battery. Explosive gases could be vented duringcharging or discharging. Use ina well ventilatedarea, awayfrom sources of ignition.

NOTE:The specialdesignedplugon thechargerwillonlyfit intothe plugon the batterybox.

1. Plugthe batterychargerintothe port ontheundersideof the batteryhousing,Figure5=5.

2. Insertthe batterychargerplug intoa standard120volthouseholdoutlet,Figure5-5. Chargebatteryfor 8 to 10hoursbeforeinitial use.Do not chargelonger than 12hours. The batteryshouldonly needto bechargeduponinitialsetupandafteranyotherextendedperiodsof non=use.

3. Aftercharging,disconnectchargerplugfromoutletfirst, thendisconnectchargerleadfrombattery.

Figure5-3: Folddownupperhandleand removetwoscrewsfrombackof housing.

f

Figure5-4:Opencovertoviewbatteryandwires.

f

J

Figure5-5:Plugchargerintobatterylead(1)andthenplugchargerpackinto120voltstandardhouseholdoutlet(2),

IMPORTANT:Alwaysplugchargerleadinto batterypack leadfirst,andthen insertbatterychargerplug into120volt standardhouseholdoutlet. Followthis orderofactioneverytimeyouchargethe battery.

12

Replacing Fuse "_The electricstartercircuit andbatteryareprotectedby a40 amperefuse,If the fuseburnsout, theelectricstarterwill not operate,If the unitfails to startwith the electricstarter,performthe followingstepsto checkthe fuseinsidethe batteryhousing:1. Openthe batterycoveras describedinReplacing

Battery,see Figure5-3.

2. Removefusefromsocketandinspectasshownin _-Figure5-6. If it is burnedout, replacewithstandardautomotive40amperefuse.

3. Carefullyplacewiringback into housing,closebatterycover,andfold upperhandleback intoplace.

NOTE: The engine can be started manually if the fuseburns out.

Off-Season StorageThe followingstepsshouldbetakento prepareyourlawnmowerfor storage.

Cleanand lubricatemowerthoroughlyas describedinthe lubricationinstructions.

We donot recommendthe useof a pressurewasheror gardenhoseto dean your unit.

Referto enginemanualfor correctenginestorageinstructions.

Coatmower'scuttingbladewithchassisgreasetopreventrusting.

. Storemowerin adry,clean area.Do notstorenext tocorrosivematerials,suchas fertilizer.

Whenstoringany typeof powerequipmentina poorlyventilatedor metalstorageshed,careshould betakentorust-proofthe equipment.Usingalight oilor silicone,coatthe equipment,especiallycablesandall movingpartsofyour lawnmowerbeforestorage.

BatteryThe batterymustbestoredwith afull charge.Extendedstorageof a dischargedbatterywill reducelifeandcapacityof the battery.

JFigure5-6:Whenreplacingfuse,useastandardautomotive7_f2ampfuse.

The engine can bestarted manuaity ifthefuse burns out,

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13

For repairs beyondthe minoradjust-ments listed here,

eentact an authorize dserviee dealer,

I

Engine runs erratic 1. Sparkplugwire loose.

2. Blockedfuel lineor stale fuel

3. Ventingas cap plugged.

4. Waterordirt in fuelsystem.

1. Connectandtightensparkplugwire.

2. Cleanfuel line; fill tankwithclean,freshgasoline.

3. Clearvent.

4. Drainfueltank. Refillwith freshfuel

5. Dirtyair cleaner. 5. Referto enginemanual

6. Carburetorout of adiustment. 6. Referto enginemanual

Engne overheats 1. Engineoil levellow. 1. Fil crankcasew th properoil.l

2. Air flow restricted. 2. RemoveNowerhousingand clean.

' 3. Carburetornot adjustedproperly. 3. Referto enginemanual

Occasional skips 1. Sparkpluggap tooclose. 1. Adiustgapto .030 inch.

(hesitates)at 2. Carburetoridle mixtureadiustment 2. Referto enginemanual

high speed improperlyset.

Idles poorly

3. Referto enginemanual

Excessive 1. Cuttingbladelooseor unbalanced. 1. Tightenbladeandadapter.BalanceVibration blade.

2. Bentcuttingblade. 2. Seean authorizedservicedealer.

Mowerwill not 1 Wetgrass 1. Do notmowwhen grassis wet wait

mulchy-rass unt aterto cut2. Excessivelyhighgrass. 2 Mowonceat a highcutting height,

j then mowagainat desiredheightorI makea narrowercuttingpath.

3. Dullblade. 3 Sharpenor replaceblade.

Unevencut 1. Dullblade. 1. Sharpenor replaceblade.

1. Checkbelt for properpulleyinstaila-

3. Damagedorwornbelt. ' 3. inspectandreplacebelt.

14

Safety Labels Found On Your Lawn Mower

mower fet any reasen,

\

15

Shown fo_rde_el_ce _

Q

Q

Shown forrelerence

16

1 75&04093 WBelt

2 73b04338 SpringLever

3 720-0230 FoamGrip

4 717-04184A SpurGear,14T-LH

5 710-0599 TT Screw,1/&20 x 0.50

6 750-04305A Spacer

7 749-04267 CrossBracket

8 687_02204 FrontBracketAssembly

9 731-05470 C@ Spacer

10 741-04136B SplitHex FlangeBearing

11 73&O4014B FrontWheel

12 71b04065 FlangeLockNut,3/8d6

13 63&04207C RearWheel

14 710-04531 Screw,1/&20x.39

15 717-04192A SpurGear,14T-RH

16 736-3084 FlatWasher

17 7867551A WheeIDustCover

18 74&04073C TransmissionBearingSupport

19 750-04317 Clip Spacer

20 716-0198 RetainingRing.875

21 687_02199 RearBracketAssembly

22 73b0320 ExtensionSpring

23 756-04151A Pulley,3.36 OD

24 736-0105 BellWasher,.375x .870x .063

25 71b0411 HexLockNut,5/16_24

26 687_02205 HandleBracketAssemblyLH

27 715-0221 DowelPin

28 61&04378 TransmissionAssembly

29 687_02206 HandleBracketAssemblyRH

To order replacement

parts, call1o800o648-6776

or visit

www.troybiff.eom

MPORTANT: For

a proper working

machine, use Factory

@proved Parts,

V-BELTSare speciaJJydesigned to engageand disengage

safely. A substitute(non=OEM) V-Belt

can be dangerousby not disengagingcompletely.

17

\

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18

1 746-04265A

2 735-04059

3 753-05096A

4 731-04204

5 747d161A

6 746_04213

7 749-04037

8 725-0157

9 73b04265

10 710-0599

11 787-01341

12 710-0654A

13 787-01346

14 756-04157B

15 756-04156B

16 736-0514

17 748-0376C

18 710=1044

19 736_0524B

20 74b0741

21 736-0513

22 750=1071

23 710_0653

24 731-05463

25 710-0260A

26 71b04063

27 731-05462

28 731-05157

DriveCable 29 731-05017A

RubberGrommet 30 710=1241

DriveControlAssembly 31 720_04072

BailCover 32 73b04264

BladeControl 33 711_04374

ControlCable 34 647_04051

LowerHandle 35 664-04045

CableTie 36 710=1174

TorsionSpring,LH 37 720_0279

TT Screw,1/4-20x,500 38 710q205

21dnchDeck 39 749-04209

TTScrew, 3/8=16x 1,00 40 736-0270

DeckBaffle 41 7361014

UpperEnginePulley 42 17032A

LowerEnginePulley 43 747_0710

FlatWasher,,885x 1,850x ,060 44 987-02055

BladeAdapter 45 731-04177

Screw,3/8-24x 1,50 46a 725=1276

BladeBell Support 46b 725_04323

21"MulchingBlade 47 725-04329

SpringWasher,,890x 1,70x ,048 48 725-04293

SleeveSpacer 49 728-0199

TT Screw,1/4-20x ,375 50 725-04347

DeckBaffle 51 725-0201

CarriageBolt,5/16-18x,62 52 731_05505

FlangeLockNut,5/16q8 731-05459

Trailshield 53 710q667A

MulchPlug

Rear Door

Screw,1/4=15x 1,00

Star Knob

TorsionSpring,RH

Door PivotRod

GrassCatcherFrame

GrassCatcher

CarriageBolt,5/16=18x 2,00

WingNut

Eye Bolt

UpperHandle

BellWasher,,265x ,75x ,062

TorsionSpring

ChuteDeflectorAdapter

HingePin

MulchPlugAssembly

SideDischargeChute

12Volt Battery

12Volt Battery

BatteryCharger

ElectricStarterHarness

Rivet

Key Switch

Key

BatteryHsg, (usedw/ref,#46a)

BatteryHsg, (usedw/ref,#46b)

Screw,#10q6 x ,750

To order replacementparts, ca[[

1-800-648-6776or visit

www.troybiJt.eom

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19

MANUFACTURER'S LIMITED WARRANTY FOR

®

The limitedwarrantyset forthbelowis givenbyTroy_BiltLLCwithrespectto newmerchandisepurchasedandusedin the UnitedStates,itsposses_sionsandterritories.

"Troy_Bilt"warrantsthis productagainstdefects inmaterialandworkmamshipfor a periodof two(2)yearscommencingon thedate of originalpurchaseandwill,at its option,repairor replace,freeof charge,any partfoundto bedefectivein materialsor workmanship.This limitedwarrantyshallonly applyif this producthasbeenoperatedand maintainedinaccordancewith the Operator'sManualfurnishedwith the product,andhas notbeensubiectto misuse,abuse,commercialuse,neglect,accident,impropermaintenance,alteration,vandalism,theft, fire,water,or damagebecauseof other perilor naturaldisaster.Damageresultingfromtheinstallationor use ofany part,accessoryor attachmentnot approvedbyTroy_Biltfor use with theproduct(s)coveredby this manualwill voidyourwarrantyas to any resultingdamage.

Normalwearpartsarewarrantedto befree fromdefects inmaterialandworkmanshipfor aperiodof thirty (30)daysfromthedate of purchase.Normalwearparts include,butare notlimitedto itemssuchas: batteries,belts,blades,bladeadapters,grassbags,riderdeckwheels,seats,snowthrowerskidshoes,shaveplates,augerspiralrubberandtires.

NOWTO OBTAIN SERVICE: Warranty service is available, WITHPROOFOF PURCHASE,through your local authorizedservicedealer. To locate the dealer in your area, check your Yellow Pages,or contact Troy-Bilt LLC at RO. Box 361131,Cleveland, Ohio 44136-0019, or can 1-866-840-6483 or 1-330-558-7220,or log on to ourWeb site at www.troybilt.com.

This limitedwarrantydoesnot providecoverageinthe followingcases:

a. The engineor componentparts thereof.Theseitemsmaycarrya separatemanufacturer'swarranty.Referto applicablemanufacturer'swarrantyfor termsandconditions.

b. Logsplitterpumps,valves,andcylindershaveaseparateoneyearwarranty.

c. Routinemaintenanceitemssuchas lubricants,filters,bladesharpening,tune_ups,brakeadiustments,clutch adiustments,deckadiustments,andnormaldeteriorationof the exteriorfinishdueto use orexposure.

d. Servicecompletedbysomeoneotherthananauthorizedservicedealer.

e. Troy_Biltdoesnot extendanywarrantyfor productssold orexportedoutsideof the UnitedStates,its possessionsandterritories,exceptthosesold throughTroy_Bilt'sauthorizedchannelsof exportdistribution.

f. Replacementpartsthatare notgenuineTroy_Biltparts.g. Transportationchargesandservicecalls.

No impliedwarranty, includingany impliedwarranty of merchant°ability of fitness for a particular purpose, applies after the applicableperiod of express written warranty above as to the parts as identi-fied. No other express warranty, whether written or oral, except asmentioned above,given by any person or entity, includinga dealer orretailer,with respect to any product, shall bind Troy-Bilt. During theperiod of the warranty, the exclusive remedy is repair or replacementof the product as set forth above.

The provisions as set forth in this warranty providethe sole andexclusive remedyarising from the sale. Troy-Bilt shall not be liablefor incidental or consequential loss or damage including, withoutlimitation, expenses incurred for substitute or replacement lawn careservices or for rental expenses to temporarily replace a warrantedproduct.

Somestatesdo not allowtheexclusionor limitationof incidentalor

consequentialdamages,or limitationson howlonganimpliedwarrantylasts,so the aboveexclusionsor limitationsmaynotapplyto you.

In noeventshall recoveryof any kind begreaterthanthe amountof thepurchasepriceof the productsold.Alteration of safety features of theproduct shall void this warranty. Youassumethe riskandliability forloss,damage,or injuryto youand yourpropertyand/or to othersandtheirpropertyarisingout of the misuseor inabilityto use the product.

This limitedwarrantyshall notextendto anyoneotherthanthe originalpurchaseror to the personfor whomit waspurchasedas a gift.

HOWSTATELAW RELATESTO THiSWARRANTY:This limitedwar-rantygh,'esyouspecificlegal rights,andyou mayalso haveother rightswhichvaryfromstateto state.

IMPORTANT:OwnermustpresentOriginalProofof Purchaseto obtainwarrantycoverage.

TROYBILT LLC, P.O. BOX 361131 CLEVELAM D, OHIO 44136-0019; Phone: 1(866} 840-6483, 1-330-558-7220